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Diagnosis and repair



DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

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31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

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31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

{tag}1033843701@


31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

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20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

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20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

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20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

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20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

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18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

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10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

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18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

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18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

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18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

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18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

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10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

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10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

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25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

{tag}1033838584@


25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

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18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

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18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

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10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

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20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

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20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

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20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

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18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

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20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

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18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

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20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

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20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

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20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

{tag}1033833083@


20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

{tag}1034681918@


10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

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18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

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18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

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29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

{tag}1034675869@


29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

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18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

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18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

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6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

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18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

{tag}1033822478@


18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

{tag}1034672880@


10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

{tag}1034666108@


8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

{tag}1034652019@


5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

{tag}1034657814@


6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

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5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.






DISASSEMBLE
1.Clamp output end of mainshaft firmly in a suitable soft-jawed vise.
2.Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3.Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4.Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.

Bearing Collets RemovalBearing Collets Removal



5.Pull bearing from mainshaft.

3rd/4th Gear Sleeve Removal3rd/4th Gear Sleeve Removal



6.Remove 3rd/4th gear sliding sleeve from mainshaft.

NOTE: Place a cloth around synchronizer assembly to catch compression springs, pressure pieces, and balls that will be released when sliding sleeves are removed.

7.Remove 3rd/4th synchronizer body to mainshaft retaining ring, place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.

Collet Retaining Ring RemovalCollet Retaining Ring Removal



8.Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9.Place shaft protector tool No. D8OL-625-4 or equivalent on end of mainshaft.

Synchronizing Body RemovalSynchronizing Body Removal



10.Place the three jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11.Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12.Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upward.
13.Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14.Position two collet halves tool No. T87T-7025-OH or equivalent, to allow them to seat in groove in 1st/2nd sliding sleeve.
15.Pass retaining ring from below over two halves and secure them to sliding sleeve.
16.Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer, and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17.On 4x4 models, remove snap ring and tapered roller bearing.

Removing Mainshaft Rear Tapered Roller BearingRemoving Mainshaft Rear Tapered Roller Bearing



18.On all models, place a suitable bearing gripper on mainshaft tapered roller bearing as shown in the Mainshaft Rear Tapered Roller Bearing Removal image, ensuring gripper is attached to bearing shoulder and bearing cage.
19.Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper as shown in the Mainshaft Rear Tapered Roller Bearing Removal image.
20.Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21.Remove synchronizer ring from 5th/reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22.Remove 5th/reverse sliding sleeve.

NOTE: Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.

23.Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear.
24.Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25.Slide retaining ring upward around collets to secure them in position.
26.Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3-jawed puller.
27.Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28.Remove reverse gear caged needle bearings from mainshaft.

1st Gear Removal1st Gear Removal



29.Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.

NOTE: An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.

30.Remove 1st gear caged needle roller bearings from mainshaft.

ASSEMBLE
1.Secure mainshaft in a suitable soft-jawed vise, then place reverse gear caged needle roller bearings on mainshaft.
2.Place reverse gear on mainshaft over caged needle roller bearings, ensuring clutching teeth on reverse gear are facing upward.

NOTE: Before installing original synchronizer ring and synchronizer body, check for excessive wear.

3.Position reverse gear synchronizer ring on taper of reverse gear.
4.Heat 5th/reverse synchronizer body, using a suitable heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
5.Position synchronizer body on mainshaft splines to allow side with deeper hub faces down and short lugs on synchronizer ring to engage gaps in synchronizer body.
6.Push or lightly tap synchronizer body down until it stops.
7.Install snap ring on mainshaft next to 5th/reverse synchronizer body.
8.Clearance between snap ring and synchronizer body should be 0.0-0.004 inch with zero clearance preferable.

NOTE: Ensure snap ring is free of burrs before checking clearance.

9.Check reverse gear endplay. Endplay must be between 0.006-0.014 inch.

Sleeve Synchronizer Body And Reverse Gear AlignmentSleeve Synchronizer Body And Reverse Gear Alignment



10.Position 5th/reverse sliding sleeve with two grooves upward over synchronizer body.
11.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against reverse gear clutching teeth, as shown in the Sleeve Synchronizer Body And Reverse Gear Alignment image.
12.Insert three compression springs with pressure pieces in recesses of synchronizer body.

NOTE: Prior to installing original springs, check springs for serviceability.

13.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
14.Place 5th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 5th/reverse synchronizer body.
15.Push 5th gear synchronizer ring downward while pulling sliding sleeve into center position.
16.Place both 5th gear caged needle roller bearings on mainshaft then install 5th gear on mainshaft over caged needle roller bearings.
17.Heat inner race of mainshaft rear taper roller bearing, using a suitable gear heater to approximately 32O° F, ensuring not to heat for more than 15 minutes.
18.Place gear on mainshaft, until it seats against stop on mainshaft.

NOTE: If necessary to drive bearing on, do not drive against bearing cone.

19.On all models except 4x4, check 5th gear endplay. Endplay should be 0.006-0.014 inch.

Installing Mainshaft Rear Tapered Roller BearingInstalling Mainshaft Rear Tapered Roller Bearing



20.On 4x4 models, install additional retaining ring in annular groove next to taper roller bearing inner race. Check 5th gear endplay. Endplay should be 0.0-0.004 inch.
21.On all models, invert mainshaft then secure at input end using suitable soft-jawed vise.
22.Place 1st gear caged needle roller bearings on mainshaft, then the 1st gear over needle roller bearing, taper side up.
23.Place 1st gear synchronizer ring on taper of 1st gear.
24.Heat 1st/2nd synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.

Installing Synchronizer BodyInstalling Synchronizer Body



25.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
26.Push or lightly tap synchronizer body down, until it stops against synchronizer ring.

NOTE: When properly installed, the word " Engine" will be visible on synchronizer body.

27.Install a suitable snap ring, on mainshaft next to 1st/2nd synchronizer body.
28.Clearance between snap ring and synchronizer body should be 0.004 inch or less, Ensure snap ring is free of burrs prior to measuring clearance.
29.Check 1st gear endplay. Endplay should be 0.006-0.014 inch.
30.Position sliding sleeve over synchronizer body, with tapered collar facing downward (toward output end of mainshaft).

Aligning 1st Gear Sleeve, Synchronizer Body And Reverse GearAligning 1st Gear Sleeve, Synchronizer Body And Reverse Gear



31.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 1st gear.
32.Insert three compression springs with pressure pieces in recesses of synchronizer body. Prior to installing original springs, check springs for serviceability.
33.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
34.Place 2nd gear synchronizer ring on 1st/2nd synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 1st/2nd synchronizer body.
35.Push synchronizer ring downward while pulling sliding sleeve into center position.
36.Place 2nd gear caged needle roller bearings on mainshaft, then install 2nd gear on mainshaft over needle bearings.
37.Heat thrust washer, using a suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
38.Place thrust washer on mainshaft and push down until it seats against stop on mainshaft. If necessary, gently tap washer to fully seat.
39.Heat 3rd gear bearing inner race to approximately 320° F, ensuring not to heat for more than 15 minutes.
40.Place race on mainshaft, then push down until fully seated against shaft stop.
41.Check 2nd gear endplay. Endplay should be 0.006-0.017 inch.
42.After 3rd gear bearing inner race has fully cooled, place 3rd gear needle roller bearings over it.
43.Place 3rd gear over needle roller bearings on mainshaft, ensuring taper of 3rd gear is facing up.
44.Place 3rd gear synchronizer ring on taper of 3rd gear.
45.Heat 3rd/4th synchronizer body, using a suitable gear heater, to approximately 320° F, ensuring not to heat for more than 15 minutes.
46.Position synchronizer body on mainshaft splines, with short lugs on synchronizer ring engaged with gaps on synchronizer body.
47.Push or lightly tap synchronizer body down, until it stops against synchronizer ring. Ensure recess in synchronizer body faces up.
48.Install a suitable snap ring, on mainshaft next to 3rd/4th synchronizer body.
49.Clearance between snap ring and synchronizer body should be 0.004 inch or less. Ensure snap ring is free of burrs prior to measuring clearance.
50.Check 3rd gear endplay. Endplay should be 0.006-0.014 inch.
51.Position sliding sleeve over synchronizer body, with smaller of two grooves facing down.
52.Align three cut away positions on sliding sleeve with three gaps on synchronizer body and three lugs on synchronizer ring. Slide sliding sleeve down until it rests against 3rd gear.
53.Push back pressure pieces, using a suitable screwdriver, then push in balls and slide pressure pieces until it rests against ball.
54.Place 4th gear synchronizer ring on synchronizer body, noting that short lugs on synchronizer ring should be located over gaps in 3rd/4th synchronizer body.
55.Push synchronizer ring downward while pulling sliding sleeve into center position.
56.Heat inner race of mainshaft front taper roller bearing, using suitable gear heater to approximately 320° F, ensuring not to heat for more than 15 minutes.
57.Place bearing on mainshaft, until it seats against its stop on mainshaft.

NOTE: An alternate method to the previous step, is to press bearing on, using bearing cone replacer tool No. T85T-4621-AH or equivalent.









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